Cord Lock Fit System for a Helmet

ABSTRACT

A helmet with an adjustable fit system is disclosed herein. The helmet includes a protective shell and the adjustable fit system. The adjustable fit system is coupled to an positioned at least partially within the protective shell. The adjustable fit system includes a frame having two cord attachment points, a cord coupled to the two cord attachment points of the frame, and a tension device releasably coupled to the cord between the two attachment points. The tensioning device is configured to adjust a distance between the two attachment points of the frame via movement of the tensioning device relative to the cord to adjust a size of the adjustable fit system. The cord may pass through the tensioning device to form a first portion between each cord attachment point and the tensioning device, and a looped second portion extending from the tensioning device away from the first portion.

CROSS REFERENCE TO RELATED APPLICATIONS

This document claims the benefit of the filing date of U.S. Provisional Patent Application 62/090,195, entitled “Cord Lock Fit System for a Helmet” to Musal that was filed on Dec. 10, 2015, the contents of which are hereby incorporated by reference.

BACKGROUND

1. Technical Field

Aspects of this document relate generally to fit adjustment systems for protective helmets.

2. Background Art

Protective head gear and helmets have been used in a wide variety of applications and across a number of industries including sports, athletics, construction, mining, military defense, and others, to prevent damage to a users head and brain. Damage and injury to a user can be prevented or reduced by preventing hard objects or sharp objects from directly contacting the user's head, and also from absorbing, distributing, or otherwise managing energy of the impact. Conventional fit adjustment systems include a rotatable ratchet, wherein rotation of the ratchet adjusts the size of the fit system.

SUMMARY

Aspects of a helmet with a cord lock fit system may comprise a protective shell and an adjustable fit system coupled to and positioned at least partially within the protective shell, the adjustable fit system comprising a frame comprising two cord attachment points and coupled to the protective shell, a cord fixedly coupled to the two cord attachment points of the frame, and a tension device releasably coupled to the cord between the two attachment points, the tensioning device configured to adjust a distance between the two attachment points of the frame via movement of the tensioning device relative to the cord to adjust a size of the adjustable fit system.

Particular embodiments of the helmet may further comprise wherein the cord passes through the tensioning device to form a first portion of the cord between each cord attachment point of the frame and the tensioning device, and a second portion of the cord extending from the tensioning device away from the first portion of the cord. The Cord may comprise a single cord extending between the two attachment points and the second portion of the cord forms a loop extending from the tensioning device. The frame may further comprise a loop clip configured to receive the loop for removable coupling. The tensioning device may comprise a spring-loaded cord lock comprising a spring and a tab configured to releasably couple the cord within the tensioning device. The frame may comprise two opposing helmet attachment end points coupled to the helmet. The frame may comprise a central helmet attachment point coupled to the helmet. The tensioning device may be integrally formed to the frame of the adjustable fit system.

According to another aspect, an adjustable fit system for a protective helmet may comprise a frame comprising two cord attachment points, a cord fixedly coupled to the two cord attachment points of the frame, and a tension device releasably coupled to the cord between the two attachment points, the tensioning device configured to adjust a distance between the two attachment points of the frame via movement of the tensioning device relative to the cord to adjust a size of the adjustable fit system.

Particular embodiments may comprise one or more of the following. The cord may pass through the tensioning device to form a first portion of the cord between each cord attachment point of the frame and the tensioning device, and a second portion of the cord extending from the tensioning device away from the first portion of the cord. The cord may comprise a single cord extending between the two attachment points and the second portion of the cord forms a loop extending from the tensioning device. The frame may further comprise a loop clip configured to receive the loop for removable coupling. The tensioning device may comprise a spring-loaded cord lock comprising a spring and a tab configured to releasably couple the cord within the tensioning device. The frame may comprise two opposing helmet attachment end points configured to couple to a helmet. The frame may comprise a central helmet attachment point configured to coupled to a helmet. The tensioning device may be integrally formed to the frame of the adjustable fit system.

In another aspect, a method of securing a protective helmet to a head of a wearer may comprise placing a helmet on a head of a wearer, the helmet comprising an adjustable fit system coupled to and positioned at least partially within a protective shell of the helmet, the adjustable fit system comprising a frame comprising two cord attachment points and coupled to the protective shell, a cord fixedly coupled to the two cord attachment points of the frame, and a tension device releasably coupled to the cord between the two attachment points, and tensioning the cord to adjust a fit of the helmet by adjusting a distance between the two attachment points of the frame by moving the tensioning device relative to the cord.

Particular embodiments may comprise one or more of the following. Tensioning the cord may comprise tensioning a first portion of the cord extending between the attachment point and the tensioning device by pulling a second portion of the cord extending from the tensioning device away from the attachment point. Pulling a second portion of the cord may comprise pulling a looped second portion extending from the tensioning device. Removably coupling the looped second portion to a loop clip on the frame.

The foregoing and other aspects, features, and advantages will be apparent to those artisans of ordinary skill in the art from the DESCRIPTION and DRAWINGS, and from the CLAIMS.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will hereinafter be described in conjunction with the appended drawings, where like designations denote like elements, and:

FIG. 1A is a rear view of a helmet having a fit adjust adjustment system;

FIG. 1B is a bottom view of a rear portion of a helmet having a fit adjustment system;

FIG. 2A is a rear view of a fit adjustment system with a looped second portion of a cord detached from a loop clip;

FIG. 2B is a rear view of a fit adjustment system with a looped second portion of a cord detachably coupled to a loop clip;

FIG. 2C is a side view of a fit adjustment system with a looped second portion of a cord detachably coupled to a loop clip; and

FIG. 2D is a close up view of a tensioning device of a fit adjustment system.

DESCRIPTION

This disclosure, its aspects and implementations, are not limited to the specific material types, components, methods, or other examples disclosed herein. Many additional material types, components, methods, and procedures known in the art are contemplated for use with particular implementations from this disclosure. Accordingly, for example, although particular implementations are disclosed, such implementations and implementing components may comprise any components, models, types, materials, versions, quantities, and/or the like as is known in the art for such systems and implementing components, consistent with the intended operation.

The words “exemplary,” “example,” or various forms thereof are used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as “exemplary” or as an “example” is not necessarily to be construed as preferred or advantageous over other aspects or designs. Furthermore, examples are provided solely for purposes of clarity and understanding and are not meant to limit or restrict the disclosed subject matter or relevant portions of this disclosure in any manner. It is to be appreciated that a myriad of additional or alternate examples of varying scope could have been presented, but have been omitted for purposes of brevity.

While this disclosure includes embodiments of many different forms, there is shown in the drawings and will herein be described in detail particular embodiments with the understanding that the present disclosure is to be considered as an exemplification of the principles of the disclosed methods and systems, and is not intended to limit the broad aspect of the disclosed concepts to the embodiments illustrated.

FIG. 1A depicts a rear view of a non-limiting embodiment of a protective helmet 2 comprising an adjustable fit system 10, a fit mechanism, or a helmet stability device, referred to hereinafter for convenience as a “fit system.” FIG. 1B provides a bottom view of a rear portion of helmet 2 comprising a non-limiting embodiment of a fit system 10, including an upside down view of an interior surface of a rear portion of the helmet 2. The non-limiting embodiment of a helmet 2 shown in FIG. 1A-B include an outer surface of a rear portion of the helmet 2 and a portion of the fit system 10, e.g., a portion to helmet that would be disposed opposite a wearer's face. A protective helmet 2 may comprise a protective shell 4 that includes one or more layers formed of one or more materials, including one or more layers of energy absorbing foam or protective shells such as expanded polystyrene (EPS), expanded polypropylene (EPP), expanded polyolefin (EPO), Acrylonitrile butadiene styrene (ABS), polycarbonate, vinyl nitrile (VN), or other suitable or similar material. Thus, the protective shell 4, whether a layer of energy absorbing foam or an outer rigid or flexible shell, can be fixed and rigid or deformable with respect to one or more of a dimension, position, size, shape, contour, or circumference of the protective shell and one or more of a dimension, position, size, shape, contour, or circumference of the wearer's head.

FIG. 1A-1B further show a non-limiting example of an adjustable fit system 10 disposed within a fixed or non-deformable protective shell 4. FIGS. 2A-2D depict various views of a non-limiting embodiment of a fit system 10 from within the protective shell 4. According to some aspects, a fit system 10 comprises at least a frame 15 and a cord 20. The frame 15 may comprise any type or combination of plastics or other materials. The frame 15 is referred to herein as a plastic frame 15 for convenience, and not by way of limitation. Accordingly, a plastic frame 15 can also be made of other suitable materials, whether natural or synthetic, including metal, fiber, textile, carbon fiber, Kevlar, or any flexible or rigid material that can be adjusted as part of the fit system to match or accommodate a size, shape, or contour of a wearer's head. As discussed in greater detail below with respect to the accompanying figures, a plastic frame 15 may be disposed within an outer helmet shell, or energy-absorbing layer. Alternatively, the plastic frame 15 may be part of an outer protective shell, as disclosed in provisional application No. 61/974,713 (the '713 patent), filed Apr. 3, 2014, titled “Adaptive Fit Helmet”, and utility patent application Ser. No. 14/613,670 (the '670 patent), filed Feb. 4, 215, the contents of which are incorporated herein by this reference. Thus, the cord lock fit system described herein could replace the fit system mechanism of the '713 patent and the '670 patent or be used in any other helmet with an adjustable fit system.

As indicated above, a fit system 10 comprises a cord 20 coupled to the plastic frame. The cord 20 may be elastic, non-elastic, and be configured with any desired amount of stretch or elasticity to accommodate a desired stretch, elasticity, or rigidity, within in the fit system. For example, the stretch or elasticity of a cord 20 can be inversely proportional a stiffness of the plastic frame 15. The cord 20 may be coupled to the plastic frame 15 at a single point, or at a plurality of points, and may be coupled to the plastic frame 15 rigidly, slidably, fixedly, removably, or any combination thereof. In an embodiment, a cord 15 comprises a first end 21 and a second end 22 opposite the first end 21. The first end 21 of the cord 20 may be coupled to a first of two cord attachment points 11 on a side rear portion of the plastic frame 15 as in FIG. 1. Similarly, the second end 22 of the cord 20 may be coupled to a second of the two cord attachment points 11 on a side rear portion of the plastic frame 15 that is offset from the first cord attachment point 11 of the plastic frame 15 coupled to the first end 21 of the cord 20.

One or more embodiments of an adjustable fit system 10 further comprise a tensioning device 25 releasably coupled to the cord 20 between the first end 21 and the second end 22 of the cord 20. FIGS. 1-2 show a non-limiting embodiment of a tensioning device 25. While a single cord 20 is shown coupled to multiple cord attachment points 11 on the plastic frame 15 and extending through the tensioning device 25, in other embodiments multiple cords such as two or more cords or any number of cords may be utilized. For example, in an alternate embodiment, separate cords may be coupled to the cord attachment points of the plastic frame 15, and each cord could then separately pass through a separate or the same tensioning device 25. In either event, a first portion 23 of the cord 20 or cords (referred to hereinafter for convenience as “cord”) comprises the portion of the cord 20 that extends between the plastic frame 15 and the tensioning device 25. A second portion 24 of the cord 20 comprises the portion of the cord 20 that extends from the tensioning device 25 away from the tensioning device 25 opposite the first portion 23 of the cord 20. As such, the first portion 23 of the cord 20 may be coupled to a side or rear portion of the plastic frame 15 and extend to the tensioning device 25. In other embodiments, one or more cords 20 may be woven through, or pass through the plastic frame 15 at an attachment point, along an entire circumference, or along or at other desirable locations of the plastic frame 15.

In non-limiting embodiments comprising a single cord 20 for tightening and loosening the plastic frame 15 to adjust the fit system 10, both ends 21, 22 of the cord 20 may be coupled to the plastic frame 15 such that two first portions 23 of the cord are formed and disposed between a different cord attachment point 11 of the two cord attachment points 11 and the tensioning device 25. In such an embodiment, a second portion 24 of the cord 20 may be disposed opposite the first portions 23 of the cord 20, and separated from the first portions 23 of the cord 20 by the tensioning device 25. According to some aspects, pulling or tightening the cord 20 causes tension in the second portion 24 of the cord 20 to be less than tension in the first portion 23 of the cord 21. Tightening and loosening the fit system may cause a dimension of the helmet to change, such as a size, shape, or circumference of the plastic frame 15, and/or a distance between the two cord attachment points 11 of the plastic frame 15. For example, a decrease in a circumference of the fit system 10 (to tighten the plastic frame 15 to a wearer's head) may occur as tension in the first portion 23 of the cord 20 increases. In some embodiments, the tensioning device 25 maintains the tension in the first portion 23 of the cord 20. More particularly, engaging the tensioning device 25 may comprise pushing a tab 26 to compress a spring 27 within the tensioning device while pulling the cord 20 to adjust the size of the fit system 10, and releasing the tab 26 so the spring 27 exerts force on the cord 20 to maintain and hold the desired tension in the cord 20 and subsequently the desired size of the fit system 10. Accordingly, a force applied by the tensioning device 25 to the cord 20 can be greater than and proportional to the stretch, elasticity, or energy stored in the tensioned cord. Similarly, a force applied by the tensioning device 25 to the cord 20 can be inversely proportional a stiffness of the plastic frame 10.

FIGS. 2A-D depict various views of a non-limiting embodiment of a fit system 10 without, or separated from, the protective shell 4 of the helmet 10. In some embodiments, a second portion 24 of a cord 20 comprises a looped second portion 24. Furthermore, one or more embodiments of a fit adjustment system 10 comprise a loop clip 19 positioned on the frame 15 to receive and detachably couple the looped second portion 24 of the cord 20 to the frame 15. In FIGS. 2A and 2C, a looped second portion 24 is shown detached and loose from the loop clip 19, while in FIG. 2B, a looped second portion 24 is shown detachably coupled to the loop clip 19. Other embodiments may comprise additional loop clips 19 to accommodate the varying sizes of loops resulting from adjusting the size of the fit system 10, or, alternatively, positioned to receive multiple second portions 24 of the cord 20 (even when not a loop). When a fit system 10 is disposed within the protective shell and oriented right side up, as when being worn by a user in an upright position, the loop clip 19 may be disposed on the plastic frame 15 above where the first portion 23 of the cord 20 is coupled to the plastic frame 15. Furthermore, the tensioning device 25 may be rigidly coupled, or integrally formed, with the plastic frame 15 as part of the fit system 10.

Various embodiments of a plastic frame 10 may comprise a single or a plurality of helmet attachment points configured to couple a fit system 10 to a helmet. For example, a non-limiting embodiment of a frame 15 comprises two rounded or hook shaped helmet attachment end points 31 and a central helmet attachment point 32 that includes two oval shaped openings in the deformable liner. Other attachment points of a frame 15 may comprise cord attachment points 11 coupled to ends 21, 22 or portions of the cord 20, and a single or plurality of attachment points where a vertical line or length of the plastic frame 15 extends down to the tensioning device 25, which can be positioned between the two ends 21, 22 of the cord 20 as it is coupled to the cord attachment points 11.

Various embodiments of a fit adjustment system 10 comprise a single cord 20 comprising first 21 and second opposing ends 22 coupled to respective cord attachment point 2 and further comprising a looped second portion 24 towards, at, or near, a center of the cord 20. In other embodiments, a cord 20 may comprise two or more separate cords, such as a first cord coupled to a left-side cord attachment point 11 and a second cord coupled to a right-side cord attachment point 11. Ends of the first and second cord may be coupled to the cord attachment points 11 while opposing ends of the first and second cords can pass through the tensioning device 25. After passing through the tensioning device 25, the opposing ends of the first and second cords may be coupled to one or more clips 19 or may be left free.

FIG. 2D provides a close-up or enlarged view of the cord 20 passing through the tensioning device 25 of a non-limiting embodiment of a fit system 10. The tensioning device 25 may comprise a spring-loaded cord lock having an opening through which the cord 20 passes. A spring 27 housed within or without the tension device may apply pressure to the cord 20 in the opening to maintain a desired level of tension in the cord 20 and a desired size or circumference of the plastic frame 15. To adjust a size of the plastic frame 15, a tab 26 the cord lock tensioning device 25 may be compressed to release the cord 20 from being held in place, and the cord 20 may be pulled through the opening in the cord lock tensioning device 25 to increase or decrease tension in the cord 20. Compression on the cord lock tensioning device 25 may then be released by releasing the tab 26 to close the opening on the cord 20 and hold the cord 20 at the new position and tension.

According to various aspects of a contemplated fit system 10, a tensioning device 25 is permanently coupled or integrally formed with an additional attachment point of the plastic frame 15 to control a shape or sizing of the plastic frame 15 as tension in the cord is adjusted. This additional attachment point may comprise any coupling of the tensioning device 25 to the plastic frame 15, such as direct coupling between the tensioning device 25 and the head of the wearer. This attachment point may comprise a single member or a plurality of members, including two or three members coupled to the tensioning device.

Also contemplated as part of this disclosure are various methods of securing a protective helmet 2 to a head of a user using the protective helmet and a fit system 10 described herein. A method may comprise placing the helmet 2 over or on the head of the user and tensioning a cord 20 coupled to the plastic frame 15 to adjust a fit of the helmet 2 by decreasing or increasing a distance between the head of the user and the plastic frame 15, and/or a distance between attachment points 11 of the plastic frame 15. The plastic frame 15 may be disposed between an energy absorbing layer 4 and the head of the user, or alternatively, the energy absorbing layer 4 can be disposed between the head of the user and plastic frame 15.

A method may further comprise tensioning the cord 20 by pulling on the cord 20 and engaging a tensioning device 25 to maintain tension in the cord 20. Engaging a tensioning device 25 may comprise pushing a tab 26 to compress a spring 27 while pulling the cord 20, and releasing the tab 26 so the spring 27 exerts force on the cord 20 to maintain the tension in the cord 20. A method may further comprise removably coupling the looped second portion 24 to a loop clip 19 on the frame 15.

Examples

One non-limiting example comprises the following:

A protective helmet 2 comprising a protective shell 4, a plastic frame 15 disposed at least partially within the protective shell 4, a cord 20 coupled to the plastic frame 15, and a tensioning device 25 releasably coupled to the cord 20. The protective helmet 2 further comprises a first portion 23 of the cord 20 disposed between the plastic frame 15 and the tensioning device 25, and a circumference of the plastic frame 15 that decreases as tension in the first portion 23 of the cord 20 increases. A second portion 24 of the cord is disposed opposite the first portion 23 of the cord 20 and separated from the first portion 23 of the cord 20 by the tensioning device 25, wherein tension in the second portion 24 of the cord 20 can be less than tension in the first portion 23 of the cord 24. The protective shell may comprise EPS. The first portion 23 of the cord 20 is coupled to a rear portion of the plastic frame 20. The plastic frame 15 comprises a loop clip 19 sized to releasably couple to the second portion 24 of the cord 20. The clip 19 is disposed on the plastic frame 15 above where the first portion 23 of the cord 20 is coupled to the plastic frame 15. The tensioning device 25 is rigidly coupled to the plastic frame 15, and the tensioning device is integrally formed with the plastic frame 15.

Another, non-limiting example of a fit system for a protective helmet comprises the following:

A plastic frame comprising 15 comprising a plurality of attachment points. One attachment point comprises helmet attachment end points 31 configured to couple the fit system 10 to a protective helmet 2. The fit system 10 further comprises a cord 20 comprising a first end 21 coupled to a first cord attachment point 11 of the plastic frame 15 and a second end 22 coupled to a second cord attachment point 11 of the plastic frame 15. A tensioning device 25 is releasably coupled to the cord 20 between the first end 21 and the second end 22 of the cord 20. The tensioning device 25 is fixedly coupled to the frame 15 at an additional coupling point, and the cord 20 comprises an elastically deformable cord 20.

A non-limiting example of a method of securing a protective helmet to a head of a user comprises the following:

Placing the helmet 2 over or on the head of the user, disposing a plastic frame 15 between the helmet 2 and the head of the user, and tensioning a cord 20 coupled to the plastic frame 15 to decrease a distance between the head of the user and the plastic frame 15. Tensioning the cord 20 comprises pulling on the cord 20 and engaging a tensioning device 25 to maintain tension in the cord 20. The tensioning device 25 is also engaged by pushing a tab 26 to compress a spring 27 while pulling the cord 20, and releasing the tab 26 so the spring 27 exerts force on the cord 20 to maintain the tension in the cord 20.

It will be understood that the embodiments disclosed are not limited to the specific components disclosed herein, as virtually any components consistent with the intended operation of a method and/or system implementation for such an embodiment may be utilized. Accordingly, for example, although particular component examples may be disclosed, such components may be comprised of any shape, size, style, type, model, version, class, grade, measurement, concentration, material, weight, quantity, and/or the like consistent with the intended purpose, method and/or system of implementation.

In places where the description above refers to particular implementations or embodiments, it should be readily apparent that a number of modifications may be made without departing from the scope and/or spirit thereof and that these principles and modifications may be applied to other such embodiments. The presently disclosed embodiments are, therefore, to be considered in all respects as illustrative and not restrictive. 

1. A helmet comprising: a protective shell; and an adjustable fit system coupled to and positioned at least partially within the protective shell, the adjustable fit system comprising a frame comprising two cord attachment points and coupled to the protective shell, a cord fixedly coupled to the two cord attachment points of the frame, and a tension device releasably coupled to the cord between the two attachment points, the tensioning device configured to adjust a distance between the two attachment points of the frame via movement of the tensioning device relative to the cord to adjust a size of the adjustable fit system.
 2. The helmet of claim 1, wherein the cord passes through the tensioning device to form a first portion of the cord between each cord attachment point of the frame and the tensioning device, and a second portion of the cord extending from the tensioning device away from the first portion of the cord.
 3. The helmet of claim 2, wherein cord comprising a single cord extending between the two attachment points and the second portion of the cord forms a loop extending from the tensioning device.
 4. The helmet of claim 3, wherein the frame further comprises a loop clip configured to receive the loop for removable coupling.
 5. The helmet of claim 3, wherein the tensioning device comprises a spring-loaded cord lock comprising a spring and a tab configured to releasably couple the cord within the tensioning device.
 6. The helmet of claim 1, wherein the frame comprises two opposing helmet attachment end points coupled to the helmet.
 7. The helmet of claim 1, wherein the frame comprises a central helmet attachment point coupled to the helmet.
 8. The helmet of claim 1, wherein the tensioning device is integrally formed to the frame of the adjustable fit system.
 9. An adjustable fit system for a protective helmet, comprising: a frame comprising two cord attachment points; a cord fixedly coupled to the two cord attachment points of the frame; and a tension device releasably coupled to the cord between the two attachment points, the tensioning device configured to adjust a distance between the two attachment points of the frame via movement of the tensioning device relative to the cord to adjust a size of the adjustable fit system.
 10. The adjustable fit system of claim 9, wherein the cord passes through the tensioning device to form a first portion of the cord between each cord attachment point of the frame and the tensioning device, and a second portion of the cord extending from the tensioning device away from the first portion of the cord.
 11. The adjustable fit system of claim 10, wherein cord comprising a single cord extending between the two attachment points and the second portion of the cord forms a loop extending from the tensioning device.
 12. The adjustable fit system of claim 11, wherein the frame further comprises a loop clip configured to receive the loop for removable coupling.
 13. The adjustable fit system of claim 11, wherein the tensioning device comprises a spring-loaded cord lock comprising a spring and a tab configured to releasably couple the cord within the tensioning device.
 14. The adjustable fit system of claim 9, wherein the frame comprises two opposing helmet attachment end points configured to couple to a helmet.
 15. The adjustable fit system of claim 9, wherein the frame comprises a central helmet attachment point configured to coupled to a helmet.
 16. The adjustable fit system of claim 9, wherein the tensioning device is integrally formed to the frame of the adjustable fit system.
 17. A method of securing a protective helmet to a head of a wearer, comprising: placing a helmet on a head of a wearer, the helmet comprising an adjustable fit system coupled to and positioned at least partially within a protective shell of the helmet, the adjustable fit system comprising a frame comprising two cord attachment points and coupled to the protective shell, a cord fixedly coupled to the two cord attachment points of the frame, and a tension device releasably coupled to the cord between the two attachment points; and tensioning the cord to adjust a fit of the helmet by adjusting a distance between the two attachment points of the frame by moving the tensioning device relative to the cord.
 18. The method of claim 17, wherein tensioning the cord comprises tensioning a first portion of the cord extending between the attachment point and the tensioning device by pulling a second portion of the cord extending from the tensioning device away from the attachment point.
 19. The method of claim 18, wherein pulling a second portion of the cord comprises pulling a looped second portion extending from the tensioning device.
 20. The method of claim 19, further comprising removably coupling the looped second portion to a loop clip on the frame. 